1. Monopropellant Micro Propulsion system for CubeSats By Chris Biddy 174 Suburban Rd Suite 120 San Luis Obispo CA 93401 (805) 549-8200 chris@stellar-exploration.com Small Satellite Conference, Logan UT 8/10/09

2. Introduction High Performance CubeSat Propulsion will open up many opportunities – Decoupling of secondary payload (CubeSat) with primary payload orbit – Quick deployment of global constellations Goal is to develop 1U propulsion system to be integrated in 3U satellite 3U CubeSat with description for each unit Propulsion Unit Electronics and battery section Payload Section

3. Why Monopropellant? Significantly higher performance (delta V) compared to cold gas Larger Thrust vs. Electric Propulsion – Needed for Orbit transfer Mature technology – Hydrazine is a known and mature hazard – New “Green” propellants still require analysis for range safety Less complicated than Bipropellant – Two separate tank and plumbing systems for fuel and oxidizer More volume efficient than Bipropellant

4. Requirements Meet CubeSat Standard – <1kg/unit – Aluminum 6061-T6, 7075 recommended – 75% of length must have rails with hard anodized surface – Not endanger primary payload Low Cost – ~$250k complete unit Address Range Safety constraints up-front – Small Propellant Quantity – Low operational pressure enables P-POD containment – Off site fueling/ Defueling as single integrated P-POD High Performance – Large delta V (~ 400m/s) – Thrust to weight ratio of 0.25

5. Design Philosophy Start with COTS components – Test and modify if necessary/possible Simplify Start with Thruster valve and design around it Develop cubic tank and cylindrical tank structure paper design in parallel – Compare theoretical performance of each – Continue design with best theoretical performance Safety to personnel is highest priority

6. Micro Propulsion Details Miniature solenoid valve used for thruster valve 2 port design with a #10-32 threaded interface Mass = 37g

7. Micro-Propulsion Unit Attachment Point for additional Units Propellant Tank P-POD Guide Rails Drain and Fill Valves (Schrader) Thruster Combustion Chamber and Nozzle Thruster Micro- Solenoid Valves

8. Propulsion System Details CNC machined tank and cap P-POD rails integrated into tank structure Mounting Flange protrudes 6.5mm from tank edge Propulsion system tank and billet blank. Propulsion system cap and billet blank

9. Propulsion System Details Tank and cap interface sealed with EDPM O-ring Stainless stud with laser drilled hole provides fluid path to thruster valve Stud uses EDPM o-ring to seal Underside of cap with o-ring installedStainless stud with EDPM o-ringUnderside of cap with stud installed

10. Propulsion System Details Thruster valve mounts to stud and seats against cap boss (middle) Schrader valve mounted to cap used for fill/drain (right) Cap shown with valve mounting studValve assembled to cap Schrader valve assembled to cap

11. Propulsion System details Thruster made from stainless steel – Prototype (heavy) thruster shown (left) Catalyst made from platinum mesh and platinum/iridium wire “screens” – Screens are stacked and held by stainless fasteners – Number of screens can be varied during testing Thruster assemblyPlatinum Catalyst

12. Propulsion System Details Dry mass fraction for propulsion system unit = 0.45 Expected delta V up to 400m/s Propulsion system assembly.

13. Test Plan Tank Burst Test – Investigate Failure Mechanism P-POD Integration – Verify smooth operation Hot Fire Test – Catalyst Function and integrity – Pressure range for proper thruster operation – Thrust measurements – Isp measurements Micro Propulsion Module and P-POD test fit Valve Cycling test under pressurization

14. Test Results Initial fit test successful Tank burst test revealed o-ring failure (Leak-Before-Burst) – Three tests performed using Nitrogen – Bolts yielded allowing main o-ring to be forced out of the groove at 2310 kPa, 2206 kPa, 2027 kPa – Consistent failure all three tests – Factor of Safety for leakage = 1.9, 1.8, 1.7 Micropropulsion system with o-ring failure

15. Test Results Stellar developed catalyst requires heating for proper decomposition Hot fire test revealed incomplete decomposition New catalyst design ready for testing

16. Future Work Propellant Management Device – Work in Progress – Testing needed Thruster Standoff Bracket Control and Navigation System Qualification Testing

17. Any Questions? Chris Biddy 174 Suburban Rd Suite 120 San Luis Obispo CA 93401 (805)549-8200 chris@stellar-exploration.com